WEISSTECH WSWP-180 180-Degree Wire Flexing Test Machine

Overview

The WEISSTECH WSWP-180 180-Degree Wire Flexing Test Machine is an electromechanical fatigue testing system engineered to evaluate the mechanical endurance of insulated wires, cables, and flexible conductors under repeated bending stress. It operates on the principle of controlled angular oscillation—subjecting specimens to symmetrical flexure between fixed angular limits (0° to 180°) while maintaining constant tensile load via calibrated hooked weights. This replicates real-world service conditions such as those encountered in retractable cords, robotic arm cabling, appliance wiring harnesses, and automotive interior looms. Unlike static tensile or compression testers, the WSWP-180 implements dynamic flexural loading aligned with internationally recognized conductor durability protocols, delivering quantitative cycle-to-failure data essential for QC release, material qualification, and design validation.

Key Features

• Six independent test stations operating in parallel—each equipped with dedicated continuity monitoring circuitry, enabling simultaneous evaluation of multiple specimens without cross-interference.
• Precise manual angle adjustment via eccentric shaft mechanism with engraved 1°-graduated aluminum dial and hardened steel pointer—ensuring repeatable positioning across test series and inter-laboratory correlation.
• Continuously variable bend frequency (10–60 cycles/min) regulated by precision potentiometer and displayed on high-contrast LCD—supporting both accelerated screening and low-speed compliance verification.
• Dual counter architecture: a global total-cycle counter (0–999,999) with presettable stop threshold, and six isolated continuity-integrated counters that log only electrically intact cycles per station—stopping counting at first open-circuit event while permitting concurrent operation of remaining stations.
• Non-marring, ergonomic handle-type clamps with micro-textured gripping surfaces—minimizing surface deformation during clamping and preventing slippage under cyclic load.
• Vertically adjustable lower fixation rod with locking thumbscrew—enabling precise control over specimen sag, effective bending radius, and neutral axis alignment per IEC/GB/UL dimensional requirements.
• Modular weight set (50 g to 500 g, six units each) with corrosion-resistant stainless steel hooks—facilitating rapid load configuration and traceable force application without external calibration dependency.
• Integrated power-loss memory function: retains preset values and current counts after unexpected AC interruption—eliminating data loss and retest redundancy.

Sample Compatibility & Compliance

The WSWP-180 accommodates round and flat insulated conductors with outer diameters ranging from 0.3 mm to 8.0 mm, including PVC, rubber, TPE, silicone, and cross-linked polyolefin insulation systems. Its mechanical architecture conforms to the geometric and kinematic constraints defined in IEC 60227-2 (PVC-insulated cables), IEC 60245-2 (rubber-insulated cables), GB/T 5013.2 and GB/T 5023.2 (Chinese national equivalents), UL 62 (thermoplastic and thermoset portable cords), and ASTM D4222 (standard test method for flexibility of insulated wire). All structural components—including frame rigidity, pivot bearing tolerance, and clamp force distribution—are validated against ISO 17025-relevant mechanical stability criteria to ensure measurement repeatability ≤ ±0.5% across accredited laboratory environments.

Software & Data Management

The WSWP-180 operates as a standalone hardware platform with no embedded firmware or proprietary software dependencies. All operational parameters are configured locally via front-panel controls, and cycle data are stored in non-volatile EEPROM. For integration into GLP/GMP workflows, raw counter outputs (total cycles, continuity cycles per station) can be manually recorded or interfaced via optional RS-232 module (sold separately) for time-stamped export to LIMS or Excel-based tracking systems. The device supports audit-ready documentation: each test record includes operator ID (hand-entered), specimen ID, applied load, bend angle, frequency setting, start/stop timestamps, and failure mode annotation (e.g., “open circuit at Station 3, 12,487 cycles”). No FDA 21 CFR Part 11 electronic signature functionality is included, consistent with its classification as a Class I benchtop mechanical tester.

Applications

• Endurance validation of power cords for household appliances (e.g., vacuum cleaners, irons, kitchen mixers) per IEC 60335-1 Annex Q.
• Qualification of flexible leads used in medical devices requiring repeated articulation (e.g., ECG cables, endoscope illumination bundles).
• Material comparison studies evaluating polymer insulation cracking resistance under cyclic strain.
• Production line incoming inspection of wire suppliers’ conformance to contractual flex life specifications.
• Root cause analysis of field failures linked to conductor fatigue, especially where solder joint integrity or strand breakage is suspected.
• Supporting UL Component Recognition (UR) and CCC certification submissions through standardized, reproducible test execution.

FAQ

What standards does the WSWP-180 directly support?
It is mechanically configured to execute test procedures specified in IEC 60227-2, IEC 60245-2, GB/T 5013.2, GB/T 5023.2, UL 62, and ASTM D4222.
Can the machine test flat ribbon cables?
Yes—provided the cable thickness remains within 0.3–8.0 mm and the bending plane aligns with the cable’s natural flex axis; custom fixture adapters are available upon request.
Is calibration required before use?
No routine calibration is mandated; however, periodic verification of bend angle accuracy (using angle gauge), frequency stability (with tachometer), and weight mass (with Class M2 balance) is recommended per ISO/IEC 17025 internal quality procedures.
Does it support automatic data logging to a PC?
Not natively—but an optional RS-232 interface module enables serial output of counter values and status flags for external capture.
What happens when one station fails during a multi-station test?
Only that station’s continuity counter halts; all other stations continue uninterrupted operation, preserving overall test efficiency and statistical validity.